- Feb 19, 2000
- 390
- 0
OK this is one of the strangest things I have ever had break on a dirtbike. I had just come in from making some laps at a local riding spot and was going to drain the oil in my 02 KDX220. I got off the bike and went to get a wrench. I got the wrench and turned around and could not believe what I saw. The whole right side of my bike was covered in oil and it was dripping down from the clutch cover. i thought, ok, the cover bolts must be loose....wrong. There was a a gaping hole in the clutch cover just in front of where the kickstarter comes out of the cases! I got some contact cleaner and some rags and started cleaning to see what was going on. Not only was the clutch cover broken, the side case was broken where the 2 parts meet and there is a hairline crack in the crevice where the sidecase curves out to mate with the clutch cover extending up to the kickstarter. My theory is that somehow the sidecase was defective and the force of kicking caused the case to flex and crack when I started the bike and then the vibrations from riding caused the case to break. I took off the clutch cover and extracted a couple of pieces of the broken case that had fallen inside. I have only had the bike 2 months and have ridden it less than 100 miles and have not laid it over, so crash damage is not a factor. I am going to be taking the bike in to my local dealer Monday and see if they will warranty this. Anyone else ever seen something similar?